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Today's Topics:

   1. Re: Unknown golf cart motor rebuild - field coil prep (Jim Husted)
   2. (no subject) ([EMAIL PROTECTED])
   3. Aerodynamic donors, was: AC motor from Toyota parts dealer


Message: 1
Date: Tue, 4 Dec 2007 11:22:36 -0800 (PST)
From: Jim Husted <[EMAIL PROTECTED]>
Subject: Re: [EVDL] Unknown golf cart motor rebuild - field coil prep
To: Electric Vehicle Discussion List <>
Content-Type: text/plain; charset=iso-8859-1

--- Tim Humphrey <[EMAIL PROTECTED]> wrote:

> Maybe so, but I'd like to see Jim's response too.

Hey Tim, all

I actually thought I sent my response to the list as
well but it went to Rod direct, so I guess I didn't
look at the address either 8^o

Anyway here's what I wrote...

Hey Rod

Well it's here now huh? 8^P

> > Jim,
> > I plan on re-wrapping the field coils with
> Carolina
> > Narrow Fabric company part number 7554-1
> >
> > It has varnish impregnated in the fiberglass.

I use the 7576-1 myself, but you might find the .005
wrap easier to re-seat the coils once varnished
I'm guessing that you won't get the wrap as tight and
pillow free as I do so the .005 will be more forgiving
8^)  It's your choice but the 7556-1 is the one I'd
advise you to use.

I use a 2 1/2 to 3 ply wrap depending on coil size for
the 6" to 7" motors.  While getting around the corners
is a little tougher with the 3/4" wrap, it'll make for
a lot less pull-throughs.  Try and de-bur the coil
from as many sharp snags the fiberglass can catch and
snag on before wrapping them.  I can tell you that
you'll need about 2 1/2 full length arm to arm pulls
(about 15 feet of wrap per coil) but you might want to
use a shorter length and overlap a splice in when you
run out.  

When you come to a lead, make sure to double back on
it so you don't leave a sliver area unwrapped.  Use
your thumb to smooth out and form it around the
paying attention to the inner area (where the pole
shoe goes).  Don't worry about any loose (pillowy)
areas that form on the front edge but focus on a
smooth tight finished edge as you work around the
Back wrapping the leads will help ease the cornering
distortions as well.  If they get bad, cut it, and
start with a new splice in, try to do this in a
straight away and not on a corner.  Once you have them
wrapped, stick a cleaned pole shoe into the hole and
see how it fits and work the corners until the shoe
fits well.  Some coils are sloppy as hell while others
can be a... well you know 8^) 

> > After wrapping I plan on using PD George Viking
> > V1630 FS

Looks like that will work well, I use a baked varnish
but this should be all you'll need.  Now, I like to
put my coils in hot as it helps in seating the coils
to the housing.  If this stuff cures super stiff or
you have tight coils you might want to find a way to
heat them up at least a little to get things plyable. 

A big issue with these (GE's - Westinghouse) motors
are the little shoes they have and they are prone to
pulling the laminations out where the bolt hole is. 
So rather than seat the coil you just seat the bolt
section which causes the fin area to pull in and
distort and the rest of the shoe is unseated.  I doubt
you'll have this issue but felt it needed a mention
8^)  BTW if you heat the coils before stripping them
it's a lot easier also.

Anyway that's my advise, and you did good homework on
the materials, so you go boy 8^)  send me a pic before
you dip them though and I'll have a look before you
lock EVerything down, don't worry I'll be gentle 8^o
Hope this helps
Jim Husted
Hi-Torque Electric

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Message: 2
Date: Tue, 04 Dec 2007 14:38:48 -0500
Subject: [EVDL] (no subject)
Content-Type: text/plain; charset="us-ascii"

Tommey, sorry, but your reports of your motor experiments are off-topic for 
the EVDL.? Your posts cause a great deal of further off-topic discussion and 
are disruptive to the list.

If you have an EV or are interested in acquiring or building one, and wish to 
discuss EVs, then the EVDL is for you.? However, please find another place to 
post your experimental motor reports.? Do not continue to post them here.


David Roden - Akron, Ohio, USA
EVDL Administrator
More new features than ever.  Check out the new AIM(R) Mail ! -


Message: 3
Date: Tue, 04 Dec 2007 11:38:53 -0800
Subject: [EVDL] Aerodynamic donors, was: AC motor from Toyota parts
Content-Type: text/plain;       charset=ISO-8859-1;     DelSp="Yes";

<<< If you take the time to look at the very bottom of this list you can
see the Cd of the prius ;)
Cd      Automobile      Year >>>

Interesting - they left out older cars, which means a 1935 Tatra T77a  
(with Cd of 0.212) would be off the radar. Looking at pictures of it,  
you can see where modern aerodynamic theory could "clean it up" for a  
Cd well under 0.2 in a car large enough to seat 6 (3 across - a really  
*big* car).


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